Foldable Sheet Blank for Handheld Tools with Blunt Vertex Safety
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Solution Overview
Problem
Existing handheld tools made from sheet-shaped materials lack stability and durability, often resulting in tools that are prone to damage and unsafe for use due to sharp edges and inadequate stress distribution, while also being costly to manufacture.
Innovation Solution
A blank for forming handheld tools with a flat, elongated shape featuring symmetrically arranged upward and downward bending lines, a blunt and rounded vertex, and a middle lane that provides stability and reduces the risk of injury, made from compostable and recyclable materials like paper or silicone, which can be easily folded into various shapes using die-cutting and scoring techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If handheld tools are made from sheet-shaped materials with simple folding lines, then manufacturing cost is reduced and ease of manufacture is improved, but stability and durability of the tool deteriorate
Solution Approach 1:
The blank is divided into multiple functional sections (handle section, intermediate section, functional section) separated by bending lines, allowing each section to be optimized independently while maintaining overall structural integrity and stability
Solution Approach 2:
The patent transitions from simple 2D folding to 3D structural formation by introducing upward bending lines that create elevated portions and vertices, adding vertical dimensionality to enhance structural stability while maintaining sheet material simplicity
2Ease of manufacture
If handheld tools are made from sheet-shaped materials with simple folding lines, then manufacturing cost is reduced and ease of manufacture is improved, but durability and resistance to damage worsen
Solution Approach 1:
The upward bending lines create blunt vertices with rounded contours instead of sharp angles, distributing stress more evenly across the structure and preventing crack propagation, thereby enhancing durability while maintaining ease of manufacturing
Solution Approach 2:
Different sections of the blank are given different structural qualities - the handle section provides flexibility, the intermediate section provides transition, and the functional section with blunt vertices provides strength and damage resistance at critical stress points
3Ease of manufacture
If handheld tools are made from sheet-shaped materials, then cost-effectiveness is improved, but safety deteriorates due to sharp edges and inadequate stress distribution
Solution Approach 1:
The blunt and rounded vertex design eliminates sharp edges that could cause injury, while the curved upward bending lines distribute applied forces across a broader area, preventing stress concentration and potential failure that could harm the user
Solution Approach 2:
The patent converts the potential harm of sharp vertices into a benefit by deliberately designing blunt, rounded vertices that maintain structural integrity while eliminating safety hazards, turning a structural necessity into a safety feature
4Loss of substance
If handheld tools are made from sheet-shaped materials, then material waste is reduced, but form-stability and structural integrity worsen
Solution Approach 1:
By introducing upward bending lines that create vertical elevation and three-dimensional form from a two-dimensional blank, the patent achieves form-stability without requiring additional material, maintaining cost-effectiveness while improving structural integrity
Data Source
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AI summary
The application provides a blank for forming a handheld tool. The blank includes an elongated sheet that includes a top surface and a bottom surface, a first longitudinal end and a second longitudinal end, a first side end and a second side end, and a circumferential edge. The circumferential edge includes a rear edge, a front edge, a first side edge, and a second side edge. The elongated sheet also includes at least one upward bending line extending, and a second upward bending segment, and a connecting segment. The elongated sheet also includes a first downward bending line and a second downward bending line.